HOW THIS INTELLIGENT MACHINE HAS BEEN AN INDUSTRY GAME CHANGER
Built exclusively by Applied Robotics for a leading Australian extrusion manufacturer, this intelligent packing machine is unique. It has been designed to accurately pick and pack aluminium extrusions at the end of the production line. Using state-of-the-art laser sensing technology, it maps 3D images of the product and identifies the most elegant way to handle it for picking and packing. With our user-friendly interfaces and control systems the client has full control over the presentation and arrangement of the product in its final pack. The end result – increased productivity and reduced labour costs.
This project was successfully completed in an ageing factory, not typically suited for automation. Many in the industry labelled the task as 'too difficult to automate'. Our competitors listed reasons why a project of this kind should not be attempted. But Applied Robotics invented a new design solution with a minimum of fuss to get the job done.
Advanced control and monitoring systems use parallel processing along multiple PC and PLC cores to analyse 3D laser scanned images, locate the target product and coordinate its handling by a pair of synchronised robots.
Key Machine Features
Extrusion Handling
Packs over 5000 different profile shapes of aluminium extrusion including a wide variety of complex shapes as well as the traditional tubes and RHS. Maintains a database of all the different extrusion types.
Data Logging
All operational data is logged. Scanned images are saved and can be retrieved. The contents, weight and length of each completed pack is logged and a report generated.
3D Laser Vision
Uses 3D laser sensing technology to build an image of the product, locate it and pick it up intelligently (avoiding collision with surrounding products)
Intelligent Pack Arrangement
The arrangement of the pack can be adjusted to provide the most stable, compact pattern. If the operator does not provide a preferred pack arrangement, the system automatically generates its own packing arrangement.
Lifting and Packing
Can lift and pack single extrusions or grouped bundles from 4 - 7 metres long.
Controllable Handling
Allows the operator to control the way the extrusions are handled to prevent damage to delicate features such as fins, hooks and exterior faces.
Destacking
Automatically indexes crates filled with the product along a conveyor to be destacked and packed for shipping.
Interchangeable Robot Grippers
Varying product types can be handled via specially designed interchangeable robot gripper plates.
Cardboard and Plastic Interleaving
Cardboard is placed between extrusion layers in the pack to protect the product. If required for long distance delivery, each piece can be separated in the pack by a woven layer of plastic of the suitable length for the extrusion.